Wiring system for electrical apparatus



Jan. 5, 1937. G. w. CARPENTER ET AL 2,066,376

WIRING SYSTEM FOR ELEGTRICAP APPARATUS Filed July 2, 1954 2 Sheets-Sheet 1 I l/vl fnlroks: C-ZZeMn'WCMpeILZZI; PIZLLMa/m l). Lula Z015;

1.5V MW Jan. 5, 1937. G. w. CARPENTER ET AL- 2,065,876

WIRING SYSTEM FOR ELECTRICAL APBARATUS Filed July 2, 1954 2 Sheets-Sheet 2 ?atentecl Jan. d, 1937 UNITED STATES PATENT WIRING SYSTEM FOR ELECTEECEL APPARATUS Delaware Application July 2, 1934, Serial No. $333555 13 Claims.

This invention relates to complex electrical apparatus and a method of assembling the same. More particularly, in a radio receiving set or the like, we provide a unitary wiring structure suitable for interconnecting all of the component parts.

Heretofore when the various operating units, tube sockets, and the like have been assembled on a radio chassis, it has been necessary to run 9 numerous interconnecting leads between the terminals and to solder the two ends of each of these leads individually to their respective terminals. The present day receiving sets with matched impedances and single-dial tuning con- 1:, trol are exceedingly difficult to align so that the optimum performance characteristics may be exhibited throughout the frequency bands towhich the radio receiver is made tunable. Radio sets which are built for short wave reception present 20 even greater problems of alignment. Hence the arrangement of the interconnecting leads becomes so critical that the set may be thrown out of balance by even a slight disarrangement thereof.

It is a prime object of our present invention to facilitate the assembling and wiring of a plurality of parts in an electrical apparatus such as a radio receiving set or the like.

Another object of our invention is to render the operations of assembling and wiring a radio receiver so simple and fool-proof that the final operations of alignment and inspection may be greatly simplified and reduced in cost.

Another object of our invention is to provide a method of assembling and wiring of a radio receiving set such that the lnterconnecting leads may be brought to; a common level at the bottom of the chassis, thus facilitating a pot-soldering operation, wherein numerous soldered in joints may be made simultaneously.

Further objects and advantages of our invention will be more fully understood from the following description when read ln connection with the accompanying drawings in which Figure 1 is an exploded view showing a portion of a radio chassis provided with lamlnations of insulating material, between which connecting leads are disposed, the bottom-most lamination having suitable hollow posts for anchorage ofthe leads at points where they may be "pot-soldered;

Fig. 2 shows a vertical section of a radio chassis in which a laminated wiring assembly is provided;

Fig. 3 shows a modification of our invention in which the laminations may be provided slots wherein the staple-shaped connecting reads may be embedded;

Fig. 4 shows a disposition of both externally and internaliy of a tubular post to which they may be anchored;

Fig. 5 illustrates a device for mounting a resistor, capacitor or the like upon two posts;

Fig. 6 is a detailed view showing portion of one of the connecting posts which we prefer;

Figs. 7 and 8 are detailed views showing two modifications of post structure;

Fig. 9 shows an arrangement including posts and clips slidably mounted on posts tor enchorage thereto of a lead from resistors, capacitors, or other apparatus unit;

Fig. 10 shows a partial bottom view of the as sembly otherwise displayed in Fig. 9;

Fig. 11 is a view of still another arrangement ofa connecting post gripped by a clip for convenient mounting of a resistor, capacitor or the like;

Fig. 12 is a view or a typical lamination, certain holes in which are spanned by our staplewire connections;

Fig. 13 is a view showing an arrangement of a tubular post over which a sleeve-dike clip has been slipped thus providing means for connecting a conductor externally; and I Fig. 14 is an end view of the assembly shown in Fig. 13.

Referring to Fig. 1, we showa portion of a radio chassis IS on which may be mounted in the usual manner such apparatus as a transformer l8, a. condenser I'Land tube sockets l8 and it. Such units are shown merely by way of example, since it is apparent that the scope of our invention is such as to apply' equally well to any apparatus units that may be assembled on a chas sis or otherwise. Beneath the platform of the chassis we preferably mount a rigid metal plate suitably spaced therefrom by hollow posts 2|. Next below the plate 20 we preferably employ a plurality of laminations 22, 23, 24, and of insulating material. Each of these laminations 5 has holes disposed therein in suitable alignment such that our improved method of wiring may be readily carried out. 1

Beginning with the bottom lamination 22,

which has the greatest number of holes, certain v interconnecting any two holes.

provided, the bottom tier being wired first. Progressing upwards, the laminations 23, 24, and 25 have fewer and fewer holes for insertion of the connecting wires. The plate 20 has holes only for the leads which project downwardly from the apparatus. If desired, however, all laminations and the plate may be punched alike, in which case certain of the holes in the upper laminations would not be used.

The tubular posts 26 are secured to the bottom lamination 22 whence they project downwardly to a common level. The post-tips and all the wires confined therein are thus conveniently positioned so as to be pot-soldered. These posts 26 need not of necessity be of metal but metal is preferred because of its low cost and mechanical strength. Furthermore, there may be some advantage in soldering the conductors to the posttips.

In carrying out the necessary assembling operations, We have found it to be convenient to provide in advance all of the necessary formed wires having their middle portions of suitable length to span the required holes in the laminations, and having end portions bend at right angles thereto. As before stated, the wiring assembly is begun by inserting wires through the rivet holes, interconnecting selected rivets across the top of the lamination 22. A bench hand may be guided in the work by using temporarily a template of any suitable sheet material having therein only sufficient holes and interconnecting slots so that when such a template is placed over the lamination 22 all posts will be concealed ex cept those which are to be interconnected by the staple-shaped wires. Obviously, the wires will be inserted only in accordance with the slots When this has been done, the template may be removed and the work passed along to another bench hand whose duty it is to superpose a spacing member 28, also another lamination 23 and a second template for guidance in dropping further stapleshaped wires into suitable posts 26 and 48. Because of the added thickness of the lamination 23 and the spacing member 28, the staple-shaped wires used by the second bench hand will have longer ends in order to reach to the bottom of each post.

In like manner the assembling operations may be continued until all the necessary wires 27 have been dropped through holes in the different laminations 22, 23, 24, and 25, each from its respective level. Finally the laminations may be packed together with a single sheet of insulation 29 separating the same from the metal subbase 20.

If desired, the assembled stack of laminations may be impregnated with any suitable insulating compound, such as wax. As an alternative, the laminations before assembling may be made of sheets impregnated with a polymerizable compound such as phenol formaldehyde resin, and after assembly the entire unit may be polymerized under heat and pressure.

The wiring unit may now be assembled with the chassis l5 and clamped thereto by means of studs such as 30, each projecting through a. hollow post 2i and bolted or riveted, as may be-desired.

It is commonly the case that a condenser pack such as 11 may have numerous connecting leads 3|. The same is true of such a unit as a power transformer Hi. If desired, these leads may all be brought out through ho es in the subbase 20 and the respective laminations of insulating material, their ends being anchored to the bottom portions of the posts 26 according to any one of a number of diflerent practices hereinafter to be described.

Referring to Fig. 2, we show in cross section how some of the staple-wire connections may be brought out to the proper posts 48 along with wires connecting directly to apparatus such as coupling transformers, tube sockets and the like, the posts being disposed immediately under such units so as to permit the projecting leads 32 to remain vertically straight.

In case it is desired to avoid the use of spacing members 28, then the laminations 23, 24, 25, etc. may be slotted as shown at 33 in Fig. 3. When these slots are provided, then the use of templates for guidance of the assembling hands may be dispensed with. The wiring unit when assembled is somewhat more compact than that shown in Fig. 2. Otherwise there is very little difference therebetween.

In certain instances it appears unnecessary to use either the spacing members 28 as shown in Fig. 1, or the slotted laminations of Fig. 3, but in place thereof round washers (not shown) may be used at the studs 30, and elsewhere, if necessary, to separate the laminations by as much as the diameter of the wires 21.

Certain alternative practices have been found i themselves may be armored if desired and may be disposed between the platform of the chassis l5 and the metal plate 20. On the other hand, if it is desired to use bare wire, then the members 15 and 20 may be separated by two sheets of insulation and bare connectors such as the staple shaped wires 2'! may be used.

In certain instances it is desirable to use laminations of transparent material such as cellophane, or the like. When such wiring assembly has been completed, it can be visually inspected for tracing the connections between the tubular posts. As an article of manufacture, this unit also possesses a certain amount of sales appeal in that it can be placed on display and suitably illuminated. An observer may then see the complexity of the wiring unit and know that 'a radio embodying so many wires in so compact and so invulnerable an assemblage must be a well built radio.

According to other modifications of our invention, the assembly of laminations with the metal plate 20 may of itself constitute the chassis, the member l5 being then dispensed with. In order to provide sufficient clearance between the downwardly projecting portions of the radio apparatus to be assembled directly on our wiring unit, we preferably employ spacing studs such as 34 (see Fig. 4) for elevating the radio apparatus unit to a suitable level.

In Fig. 4 we have shown a detail of one arrangement in which a conductor 35 may be interposed between two laminations 35 of insulating material and two laminations 31 of metal, forming an electrostatic shield. The downwardly bent ends of the conductor 35 may then be brought out through the rivet shaped post I8 in the manner heretofore described. An additional conductor 39 may, if desired, be brought from a terminal of any apparatus unit through a series of matched holes in the various lamina- I tlons and hitched to the lower part of the rivet post 38 by insertion through an orifice 40 therein. The head of the rivet post 38 is seated against the upper side of the lamination 22 and opposing it is another tubular rivet 65 which fits tightly over the shank of the post 38.

Referring to Fig. 5 we show a convenient arrangement for attaching a resistor 4| or the like to two of the rivet shaped posts 42.. The posts are preferably of such formation that before assembling with the laminated sheet 22, each has one'fiange only, specifically, the flange 43. This is more clearly shown in Figs. 11 and 13. After assembling, however, a flanged head 44 is formed so as to permanently secure the rivet to the lamination. The wire terminals 45 of the resistor ll may conveniently be looped and then inserted within the body of each tubular post 42 there subsequently to be soldered.

In Fig. 6 we have shown an enlarged prospective view of a modified form of rivet post. The

'tip portion of this post is formed with two retion of tubular rivet posts 48 in which the end is tapered. The restriction of the hole in the rivet is desirable so as to confine the wires more compactly, thus facilitating the soldering thereoi. The taper on the end of the rivet is also convenient in case it is desired to slip a metal collar thereover, as shown in Figs. 13 and 14.

, Another form of post is shown in Fig. 8. It comprises a long tubular rivet 49 which may be positioned opposite a hole in the lamination 22, another rivet 50 being inserted therein and forced into the upper portion of the rivet 49. The rivet 49 may be provided with an opening 5| thus giving access to the wires therein and permitting inwise.

spection thereof in case they should need to be identified by the color of the insulation or otherrivets, may, if desired, be made from sheet stock.

In Fig. 9 we have shown an arrangement for holding a resistor at conveniently near the upper portion of its assembly with the rivets. Clip members 56 are provided which are so formed as to slip over the body of a rivet. The bottom portion of the clip 56 is formed into a hook for insertion within the rivet. Small holes 51 are also provided, the top and bottom of the clip thus permitting the pig-tails of a resistor to be threaded therethrough.

Still another form of clip 59 is shown in Fig. 11 where the bottom portion is also formed into a hook in the same manner as that shown for the clip 55. The clip 59, however, has an upwardly projecting-formed end 60 for assembly with a resistor by soldering if desired. Lugs 6| are also provided for grasping the body of the rivet.

In Fig. 12 we have shown a detail of the assembly with our laminations of certain stapleshaped wires 21a wherein it is necessary to bend the middle portion in order to avoid contact with another staple 21b. In such instances it may be convenient to cement the wire to the lamination, as at the point 62. thus preventing dislocation of Rivet 49, as well as some of the other the wire 21a and possible contact with other wires.

4 The clip 63 shown in the two views of Figs. 13 and 14 is of convenience in holding one or more conductors such as 39 adjacent the bottom end of a rivet.

It will be seen that our construction lends itself to an operation of pot soldering" such as disclosed in a Patent 1,837,962, issued December 22, 1931 to Hensgen. Our construction is even more convenient than that of Hensgen in that all of the soldered joints may be made, if desired, at one time by immersion of the rivet tips in a single bath of molten solder. It is unnecessary, therefore,to provide separate receptacles for the solder as shown in the Hensgen patent. The reason for this is that the rivet tips with the assembled wires, clips, etc., are positioned according to our invention at a lower level than that of any of the remaining apparatus of the radio set, other than, possibly, the skirt of the radio chassis. This arrangement does not, however, necessitate a pot-soldering operation. If hand soldering of the leads were practiced for any reason, even the hand work would be greatly facilitated by the accessible arrangement of the wire ends at the tips of the I tubular posts.

Although we have described herein various specific means for accomplishing the objects of our invention and we have pointed out various conveniences that may be resorted to in the operations of assembling radio apparatus, these are given merely by way of example and are not to be construed as limitations to the scope of our invention. Other modifications will suggest themselves to those skilled in the art. Our invcntion, therefore, is not to be limited except insofar .as is necessitated by the prior art and by the spirit of the appended claims.

We claim as our invention:

l. A wiring system for electrical apparatus comprising a stack of oriflced laminations, a plurality of tubular members carried by at least one of said laminations and extending through at least one of said orifices and terminating at a point remote from the outermost surface of said stack, a plurality of preformed U-shape conductors disposed with their middle portions confined between said laminations and having their parallel portions projecting through selected ones of said tubular members, and means for bonding the ends of the parallel portions that are confined within any one tubular member.

2. A system v in accordance with claim. 1 in which the end portions of said conductors are disposed at a common level suitable for potsoldering.

3. A system in accordance with claim 1 in which one at least of said tubular members has an opening along its shank for inspection and access to the conductors which it contains.

4. A system in accordance with claim 1 in which. one at least of said tubular members is formed with a plurality of inwardly bent wireretaining clip portions.

5. A system in accordance with claim 1 in which one at least of said. tubular members is metallic and is provided with means including an over-fitting clip member at the end of its shank, whereby, after soldering, one or more external leads maybe bonded together with the tubularmember and its confined conductors.

6. A system in accordance with claim 1 in which one at least of said tubular members is tapered at the end of its shank thereby to aflord more intimate contact between the contained conductors.

7. A system in accordance with claim 1 in which preformed slots are provided between certain of the orifices of said laminations thereby to provide channels for said conductors.

8. A system in accordance with claim 1 in which said tubular members are aifixed to the inner surface of the outermost lamination.

9. A system in accordance with claim 1 in which metal sheets constituting an electrostatic shield for said conductors are interleafed between alternate of said laminaticns.

IOFA system in accordance with claim 1 in which the middle portions of said conductors are disposed at various levels and the end portions terminate at a common level suitable for pot soldering.

11. A wiring system for electrical apparatus comprising a stack of orificed laminations, a. plurality of flanged tubular members, the flanges of said tubular members being aflixed to one of said laminations and the body of each tubular member extending through at least one of'said orifices and terminating at a point remote from the outermost surface of said stack, a plurality of preformed U-shape conductors disposed with their middle portions confined between said laminations and having their parallel portions pro- Jecting through selected ones of said tubular members, and means for bonding the ends of the parallel portions that are confined within any one tubular member.

12. A system in accordance with claim 11 in which some at least of said tubular members are assembled with other flanged tubular members by forcing the stems of the former into the openings of the latter thereby to dispose their respective flanges against opposite faces of the lamination on which they are mounted.

13. A system in accordance with claim 11 in which each of said tubular members is first formed with a flange intermediate the two ends thereof and a second flange is formed at one end after assembling with its supporting lamination thereby to dispose its two flanges against opposite faces of said lamination.

GLENN W. CARPENTER. WILLIAM D. LA RUE. 

